JP5777720B2 - Diagnostic system and method for monitoring the operational status of turbine machine components - Google Patents

Description

  The present invention relates generally to monitoring the operating environment of a turbine, and in particular to monitoring the operating state of a component capable of transmitting data relating to the state of individual components. In addition, the present invention relates to the use of a non-intrusive measurement system that monitors the operational status of turbine machine components.

  Gas fired turbines are used in a variety of applications, such as driving generators in power plants or propelling ships or aircraft. Combustion temperatures in modern gas turbine engines continue to rise in response to demand for higher efficiency engines. Superalloy materials have been developed to withstand the corrosive high temperature environment present in gas turbine engines. However, even superalloy materials cannot withstand prolonged exposure to the hot combustion gases of current generation gas turbine engines without some form of cooling and / or thermal insulation.

  Thermal barrier coatings are widely used to protect various hot gas path components of gas turbine engines. The reliability of such coatings is critical to the overall reliability of the machine. The design limits of such coatings are mainly determined by laboratory data. However, verification of the thermal barrier coating behavior when subjected to stress and temperature in the actual gas turbine environment is essential for a better understanding of the coating limits. Such real-world operating environment data is very difficult to obtain, especially for components that move during engine operation, such as turbine blades.

  Despite the extreme sophistication of modern turbine engines, such as power generation gas turbines or commercial and military aircraft engines, designers and operators have little information about the internal status of the turbine engine components in operation. This is due to severe operating conditions. This harsh operating condition has hindered the use of conventional sensors to collect reliable information on critical engine components.

  The ongoing quest to increase gas turbine efficiency through improved fuel efficiency and performance (increased thrust) requires an increase in the engine operating temperature of the turbine engine. Although the use of materials with improved engine design and high temperature performance provides a solution to fuel efficiency and performance, reliability issues remain. Materials that are exposed to the hot gas path are becoming closer to the material design margin and therefore require validation of the design model and development of material predictions.

  Turbine engines are composed of a wide range of component materials with various exposure temperatures, failure modes, and usage. Furthermore, the gas turbine environment is characterized by high temperatures, high centripetal acceleration to the rotating elements, and is often surrounded by highly conductive metallic materials. This complicates the introduction of sensors that monitor the real-time status of parts, including critical elements such as rotating disks and blades. The current state of the art for obtaining design data from rotating parts, such as rotating blades, is the modification of disks and rotors to send leads from the blades to the slip ring or lower temperatures and centrifugals than the blades. A telemetry system located at the end of the rotor with load is included. Disks and rotors are expensive and long lead time turbine components. That modification can often cause a significant reduction in rotor life. Changing the rotor costs millions of dollars, requires a complete disassembly of the turbine engine, and requires a long-term outage of over a month. Power companies typically lose about a million dollars a day when the turbine does not generate electricity. For this reason, long term outages are undesirable.

  Surface mapping techniques, such as infrared and microwave reaction measurement techniques, are used to obtain real-time information from the rotating parts in the turbine compressor and turbine parts without the need to modify the disks and rotors. For example, infrared cameras are used to obtain temperature mapping data for various parts, including rotating blades and stationary blades. In addition, non-intrusive stress measurement systems, also known as blade tip-timing measurements, use electromagnetic radiation, often infra-red or microwaves, to make a moving blade excursion or A reaction measurement technique for measuring vibration modes is provided. However, without local calibration, the sensitivity and accuracy of such surface measurement techniques is not sufficient.

  A wireless telemetry system that includes a point sensor mounted directly on a turbine component can provide a more accurate measurement of component temperature and vibration. However, such systems provide information only about the point locations where they reside and only about the parts on which these systems are located.

Embodiments of the invention disclosed and claimed herein combine high fidelity data acquired by multiple point sensors with wide area data associated with multiple identical parts and acquired simultaneously by surface measurement techniques. Consisting of a diagnostic system. Calibration of surface measurement techniques with multiple point sensors placed in the field of view above multiple identical parts provides high fidelity data from a large surface area of multiple turbine parts. To date, data retrieved from multiple turbine components using such multiple wireless point sensors is combined with data obtained via non-intrusive diagnostic equipment to provide a more accurate surface mapping technique. It never happened.
The main means of the present invention is as described in claims 1, 11 and 16 in the claims. That is,
“A diagnostic system for monitoring the operating state of a turbine machine component, wherein the diagnostic system is a non-contact sensor that is disposed relative to the turbine machine at a distance from the turbine machine component and detects the operating state of the turbine component. A non-contact sensor that monitors a defined area of the part determined by the field of view of the sensor and generates a data signal representative of the operating state; and mounted on the turbine part, on the turbine part A wireless point sensor arranged at predetermined coordinates with respect to a component, wherein the wireless point sensor monitors the same operating state as the non-contact sensor and generates data or a data signal representing the operating state; , said a non-contact sensor and the wireless point sensor and data acquisition and processing controller coupled in data communication, Serial using said operational state data from the wireless point sensor, the non-contact sensor or the non-contact sensor and a said controller is configured to calibrate the data received from the non-contact sensor, the The operating state is detected in a first estimated accuracy range, and the wireless point sensor is configured to detect the operating state in a second estimated accuracy range higher than the first estimated accuracy range. Diagnostic system. "
Or “a non-contact sensor for monitoring the operating state of a turbine machine component, which is disposed relative to the turbine machine at a distance from the turbine machine component and detects the operating state of the turbine component. A non-contact sensor for monitoring a defined area of the part determined by the field of view of the sensor and generating a data signal representative of the operating state; and mounted on the turbine part; A wireless point sensor located at a predetermined coordinate relative to the component and in a defined area monitored by the non-contact sensor , monitoring the same operating state as the non-contact sensor And at least one wireless point sensor for generating a data signal representing the operating state, the non-contact sensor and the wireless point sensor A data acquisition and processing controller is connected by data communication, in comparison with the high-fidelity data or data signals generated by the wireless point sensor, calibrating the low fidelity data or data signals generated by said non-contact sensor The non-contact sensor provides a data or data signal that is less faithful to the data or data signal generated by the wireless point sensor, and wherein the wireless point sensor Is a diagnostic system configured to provide a high fidelity signal compared to the data or data signal generated by the non-contact sensor. "
And "a diagnostic method for monitoring the operational state of a turbine machine component, wherein the operational state associated with the component is detected from a fixed position spaced from the component over a defined area of the turbine machine component; Detecting the same operating state associated with the part from at least one position on the part having predetermined coordinates within the defined area on the part; and taking the fixed position and interval. Generating low-fidelity data or data signal representative of the operating state from a position, generating high-fidelity data or data signal representative of the same operating state from the at least one point on the component; to calibrate the high fidelity data or and the data signal and the low fidelity data and data signal by comparing the low Tadashi Processing the data or data signals and high fidelity data and data signals, the diagnostic method comprises a. "A.

1 is a cross-sectional view of an exemplary combustion turbine in which embodiments of the present invention are used, and an exemplary monitoring and control system that collects and analyzes part data from the combustion turbine. 1 is a schematic diagram of a turbine blade stage and a non-contact sensor arranged to detect the operating state of the turbine blade. 1 is a schematic diagram of a turbine blade equipped with a wireless telemetry point sensor. FIG. 6 is a schematic illustration of a turbine part surface data map image that maps the surface state of a part, where such a map varies across the blade surface in terms of its identity, for example, temperature, strain, vibration frequency, gas pressure or gas composition. FIG. FIG. 4 is a process diagram illustrating steps in a method for monitoring the operational state of a component of a turbine machine.

  FIG. 1 illustrates an exemplary combustion turbine 10, for example, a gas turbine used for power generation. The combustion turbine 10 includes non-contact sensors and points located at various locations to monitor the operating states of a plurality of fixed and moving parts of the turbine machine 10 and diagnose the performance of these various parts. A sensor is incorporated. Embodiments of the present invention can be used with the combustion turbine 10 or in numerous other operating environments and for various purposes recognized by those skilled in the art. For example, these embodiments are used in the airplane engine and automotive industry to monitor various operating conditions of stationary and moving parts. As will be explained in more detail below, multiple sensors may have temperature configurations, vibration modes (deflection, torsion, elongation, etc.), strain, acceleration, and gas content of fluid flowing across or across such components. , And various other operating conditions. For purposes of explaining the claimed and disclosed embodiments of the present invention, it will be described to monitor or measure the temperature and vibration mode of a component, but those skilled in the art will recognize that the embodiments of the present invention monitor other operating conditions. You will understand that it can be used to

  Returning to FIG. 1, the combustion turbine engine 10 includes a compressor 12, at least one combustor 14 (removed), and a turbine 16. The compressor 12, combustor 14, and turbine 16 are sometimes collectively referred to as a gas turbine engine or combustion turbine engine or turbine machine. The turbine 16 includes a plurality of blades 18 fixed to a rotatable central shaft 20. The plurality of stationary blades 22 are disposed between the blades 18 and are sized and shaped to guide air onto the blades 18. The rotor blades 18 and stator vanes 22 are typically nickel or cobalt based alloys and are coated with a thermal barrier coating 26, such as yttria stabilized zirconia. Similarly, the compressor 12 includes a plurality of moving blades 19 disposed between the respective stationary blades 23.

  During use, air is drawn through the compressor 12. The air is compressed by the compressor 12 and driven toward the combustor 14. The combustor 14 mixes air with fuel and ignites it to form a working gas. This working gas typically exceeds about 1300 ° C. This gas expands through the turbine 16 and is guided across the bucket 18 by the vanes 22. As the gas passes through the turbine 16, it rotates the rotor blades 18 and the rotor shaft 20 and transmits available mechanical work through the shaft 20. Combustion turbine 10 further includes a cooling system (not shown). The cooling system is sized and shaped to supply coolant, such as steam or compressed air, to the blade 18 and the vane 22.

  The environment in which the rotor blades 18, 19 and the stator blades 22, 23 operate is particularly harsh and they are exposed to high operating temperatures and corrosive atmospheres, which causes the seriousness of the rotor blades 18, 19 and the stator blades 22, 23. Deterioration may occur. This is particularly possible if the thermal barrier coating 26 breaks or deteriorates. In addition, components, such as blades 18, rotate at high speeds, such as 3,600 rpm, and are subject to vibration, twisting, stretching, and various other mechanical stresses.

  Embodiments of the present invention are advantageous. This is because these embodiments allow the component to be configured to transmit data representing the state of the component during operation of the combustion turbine 10. For example, the blades 18, 19, the stator blades 22, 23, and the coating 26 are configured to have a plurality of point sensors 50 that transmit component specific data, and these data are in operation for each component. The data is directly monitored to determine each state of the and create a preventive maintenance schedule. As will be described in more detail below, the blades 18, 19, the vanes 22, 23, and the coating 26 are equipped with a plurality of point sensors that detect specific operating conditions of these components. In addition, the turbine machine 10 includes a non-intrusive measurement system that includes a plurality of non-contact sensors 24 and 31. These non-contact sensors 24 and 31 similarly measure or monitor the operating state of the same turbine machine component monitored by the point sensor 50. As described below, point sensor 50 is used to provide real-time calibration for non-contact sensors 24 and 31. For purposes of describing embodiments of the invention, the monitoring of turbine and blade operating conditions is described, but other turbine components such as combustion baskets, combustion nozzles, transfer components (eg, ducts), and The ring segments can be monitored as well.

  FIG. 1 further illustrates a schematic diagram of an exemplary monitoring and data acquisition system 30 used in accordance with various aspects of the present invention. System 30 includes antenna 32, receiver 33, processor or CPU 34, database 36, and display 38. The processor 34, database 36, and display 38 are conventional components, and the antenna 32 and receiver 33 have performance specifications that are functions of various embodiments of the present invention. For example, the antenna 32 and receiver 33 may receive wireless telemetry data transmitted from multiple transmitters deployed at various locations throughout the combustion turbine 10, as will be described more fully below. Selected.

  In accordance with an embodiment of the present invention, multiple sensors are embedded in the respective coatings of multiple components in the combustion turbine 10. In an alternative embodiment, the sensor is mounted or deposited on the surface over the part, in particular over an area where a thermal barrier coating of the part is not required, for example over a part contained within the compressor 12. The exemplary sensor embodiment is used to communicate data to the system 30 regarding component physical performance or operating characteristics and / or component coating characteristics and operating parameters of the combustion turbine engine 10. The present invention further includes the plurality of non-contact sensors 24 and 31 described above. Non-contact sensors 24 and 31 are generally spaced from the part and detect or measure operating conditions over a defined area or surface area of the part. Both embedded or surface mounted sensors (also referred to as “point sensors”) and non-contact sensors are coupled to acquisition system 30 for transmitting data or data signals representing operational state measurements. .

  For example, exemplary point and non-contact sensors detect the surface temperature of a part, measure the gas content or concentration in the combustion gas flow across the part coating, and measure strain across the part area. Measure, measure vibration or deflection (deflection, twist, elongation) of the part, or measure crack formation in the part or coating. Those skilled in the art will recognize other uniqueness and / or characteristics of components or component coatings that are measured and / or detected in accordance with aspects of the present invention.

  It will be appreciated that various sensor configurations can be embedded in a thermal barrier coating, for example, the blade 18 of the turbine 16 or the thermal barrier coating 26 of the stationary blade 22 in accordance with aspects of the present invention. US Pat. No. 6,838,157, which is hereby incorporated by reference, describes gas turbine components used to deposit sensors according to aspects of the present invention, such as blade 18 and static Various embodiments of a method for measuring wings 22 are described. This patent discloses various methods of forming grooves in the thermal barrier coating, forming sensors in the coating, and depositing backfill material in the grooves over the coating. These method and component embodiments are used to form the high performance components disclosed herein.

  US Pat. No. 6,576,861, which is a part of this specification, is used to arrange embodiments of multiple sensors and sensor connectors with multiple transmitters according to aspects of the present invention. A method and apparatus are disclosed. In this regard, the methods and apparatus disclosed therein can be used to pattern fine sensor and / or connector features of about 100 to 500 microns without the need to use a mask. By depositing these features using conductive materials, resistive materials, dielectric materials, insulating materials, and other application specific materials, multiple multilayer electrical circuits and sensors are formed. It will be appreciated that other methods may be used to deposit multilayer electrical circuits and sensors according to aspects of the present invention. For example, thermal spraying, vapor deposition, laser sintering, and lower temperature curing of the sprayed deposition material may be used as well as other suitable techniques recognized by those skilled in the art.

  In accordance with embodiments of the present invention, a plurality of point sensors 50 may be used to monitor component specific or coating specific conditions as well as to collect other data related to the operation or performance of the combustion turbine 16. It can be deployed at multiple locations within the combustion turbine 10. For example, FIGS. 1 and 3 show that one or more sensors 50 are embedded in each thermal barrier coating 26 of one or more blades 18, 19 or stationary blades 23 of turbine 16. It will be appreciated that the sensor 50 may be embedded in a thermal barrier coating of other components of the turbine 10 from which component specific and / or coating specific data is to be obtained.

  FIG. 3 shows a schematic plan view of the blade 18 having, as an example, one sensor 50 coupled to the blade 18 and a connector 52 connecting the sensor 50 to the transmitter 54. The transmitter 54 may be configured to induce engine power by inducing power using electromagnetic radiation and a corresponding transformer, or from a source, such as heat or vibration, in the turbine 16 during operation of the combustion turbine 10. By recovering energy, you are given power. For example, the transmitter 54 can be separated from the blade 18 and placed, for example, inside a disk (not shown) to which the plurality of blades 18 are attached. In this regard, the transmitter 54 is maintained in a cooler location outside the hot gas path. This will allow the circuit functionality required for wireless transmission. Placing the transmitter 54 away from the blade 18 allows the use of an external power source that provides power to the transmitter 54 without the use of a battery or induction. A power supply can also be attached to the sensor 50 to provide additional functionality to the sensor 50. This additional functionality may include mechanical actuation as a result of feedback in response to the output from sensor 50. Such an integrated system is applicable for real-time gap control on parts, eg ring segments.

  In other alternative embodiments, a coating is deposited on the surface of the vane 23, a groove is formed in the coating, and the sensor 50 and connector 52 are deposited in the groove. A protective coating is deposited over sensor 50 and / or connector 52. Since the connector 52 can extend from the sensor 50 to a termination location, such as the peripheral end of the vane 23, the distal end 53 of the connector 52 is exposed for connection to the transmitter. Sensor 50 and connector 52 can be placed on stationary blade 23 so as to minimize adverse effects on stationary blade 23 aerodynamics. One or more sensors 50, such as strain gauges or thermocouples, can be deposited, for example, on one or more turbine or compressor blades 18,19.

  Various embodiments of components to which the above-described instruments are attached, such as the stationary blades 22, 23 and the rotor blades 18, 19, including the sensor 50, and the parts to which such instruments are attached are co-pending US This is described in more detail in patent application Ser. No. 11 / 521,175. This entire US patent application is hereby incorporated by reference.

  Embodiments of the present invention allow the data acquisition system 30 to collect and store historical data regarding various operational states of the combustion turbine 10. This may be, for example, a piezoelectric device configured to provide a continuous data flow representing load conditions and stresses, vibration frequencies and temperatures experienced by various components within the turbine 16 or compressor 12 and / or This is accomplished by depositing other sensors 50 and continuously querying the status of the turbine 16 or compressor 12. This data is associated with data representing part wear and is used for preventive maintenance or other corrective actions.

  Referring again to FIG. 1 and with reference to FIG. 2, a non-intrusive measurement system including non-contact sensors 24 and 31 is shown. The non-contact sensors 24 and 31 are mounted on the casing 58 of the turbine machine 10 and are disposed corresponding to the operating components, for example, the moving blades 18 and 19 and the stationary blades 22 and 23. Such non-intrusive sensors 24, 31 are infrared cameras that detect the surface temperature of the component, or infrared devices, radio frequency devices, or microwave devices that provide data related to the vibration mode of the component. However, other operating conditions can be monitored for the purpose of diagnosing the state of the turbine machine 10. As described in US Pat. Nos. 6,062,811 and 6,200,088, both of which are hereby incorporated by reference, such non-contact sensors are: Provide telemetry capability that can be linked to a data acquisition system to provide an online monitoring system.

  With respect to stationary or rotating parts of the turbine machine 10, the non-contact sensors 24 and 31 are arranged at a determined time interval and for a given dwell time or duration during which state measurement or data retrieval takes place, It is configured to obtain measurements of a plurality of blades 18, 19 or stationary blades 22, 23 in the compressor stage. The diagnostic system includes a plurality of non-contact sensors for each turbine stage or compressor stage and monitors a plurality of different operating conditions for each stage. As known to those skilled in the art, these non-contact sensors are typically located relative to the blades 18, 19 or vanes 23 in the turbine stage or compressor stage so that the sensors 24, 31 are measured. A plurality of blades or vanes are in the field of view of the sensor for any duration when acquiring. In this way, sensors 24 and 31 can simultaneously obtain measurements for a plurality of the same type of components in the turbine stage or compressor stage for a given duration.

  In one embodiment, the sensors 24, 31 may measure a predetermined combination of blades 18, 19 or vanes 22, 23 in a given stage for the entire stage of the blade or vane. Obtained by representative measurement or monitoring of operating conditions. There are 72 blades or vanes in a given turbine stage, so that the sensors 24, 31 take measurements for one or more blades in one turbine stage or compressor stage. Composed. Preferably, measurements are taken from four (4) to eight (8) blades 18, 19 or stationary blades 22, 23 per stage, and the same blade or Obtained from a stationary blade. Thus, for at least rotating blades 18, 19, these measurements can be adjusted with the rotational speed of the turbine blade stage or compressor blade stage, so that the sensors 24, 31 19 or the operating state of the same blades 18 or 19 in the turbine or compressor stage. As known to those skilled in the art, the radial position (also referred to as the root position on the shaft) of each blade 18, 19 on the shaft 20 is known and is a given time during operation of the compressor 12 and the turbine 16. If the rotational speed of the shaft 20 (ie, the number of revolutions per minute) is known, the positions of the blades 18 and 19 with respect to the sensors 24 and 31 can be accurately predicted, and measurement values can be obtained from the same blade.

  As the blades 18, 19 rotate through the field of view of the sensors 24, 31, these sensors detect operating conditions on both sides of the component, including the pressure side and vacuum side of the blades 18, 19. With respect to the sensors 24 and 31 used to detect the operating state of the vane 23, multiple sensors can be used to deal with both sides of such components. As shown in FIG. 2, the field of view of the sensors 24, 31 defines regions 60, 62 where motion conditions are detected on the surfaces of the blades 18, 19 or the stationary blades 22, 23. For infrared sensors used to detect temperature, this defined area encompasses the entire side of the blades 18, 19 or vane 23 as shown in FIG. 2 and is a radio that detects vibration modes. For frequency or microwave sensors, the defined area includes the tips of the blades 18, 19 or the stationary blades 22, 23 as shown in FIG.

  Referring again to FIG. 1, non-contact sensors 24 and 31 are linked to a data acquisition and control system 30 that transmits signals and / or data representing component operating state measurements. Sensors 24, 31 are linked to system 30 via electrical leads or equipped with wireless telemetry capabilities and transmit data to system 30.

System 30 includes a database 36 and data received from sensors 24, 31 or 50 is stored in database 36. In addition, the system includes a processor 34 that is programmed to analyze data received from the sensors 24, 31, or 50. As known to those skilled in the art, the processor is programmed to generate and display in real time a surface map of a defined area 60 or 62 that is monitored by a non-contact sensor, which surface map is detected across the map. Displays the operating status. If an operating condition is detected for multiple blades 18 or 19 or multiple stationary blades 23 within the indicated duration, processor 34 analyzes the data to analyze one turbine stage or compressor stage. It is configured to evaluate the condition of individual components therein and / or the overall condition of the turbine stage or compressor stage. In addition, the processor 34 evaluates the state of one component or the stage in which the component functions in consideration of historical data representing the operational state over time. For example, the processor may diagnose the risk of failure associated with a particular operating condition.

  Non-contact sensors 24, 31 generate signals that represent the operating state of the part, characterized as a large or surface area low fidelity signal, as compared to the high fidelity signal generated by point sensor 50. The term “large area” or “surface area” refers to a defined area of the part that is much larger than the area of the same part monitored by the point sensor 50 located in the field of view of the non-contact sensor 24 or 31. The term is used to describe a sensor that measures operating parameters. That is, the point sensor 50 disposed on the blades 18, 19 and the stationary blades 22, 23 is an operating condition that is more accurate or is a high accuracy data of a small area that is closer to the true measurement of the operating condition. A signal including the measurement value may be generated. For example, a thermocouple sensor or strain gauge mounted on the blades 18, 19 or the stationary blades 22, 23 monitors an area that is ¼ of an inch square and is generated by non-contact sensors 24 and 31. It produces more accurate state measurements, such as temperature and vibration data, than the measured data. When acquiring data from an infrared camera, a reference temperature is required to calibrate the temperature recorded by the camera. Without calibration, the accuracy of the data is ± 20 ° C., but using a calibration thermocouple in the camera's field of view, the accuracy can be ± 6 ° C. This is a significant improvement in temperature measurement. In one embodiment of the invention, this high fidelity data generated by the point sensor 50 calibrates the non-contact sensors 24, 31 or calibrates the data generated by the sensors 24, 31 to provide a more detailed and advanced Used to deploy accurate surface mapping analysis or diagnostic techniques in real time.

  Using the data obtained from the point sensor 50, calibration of the non-contact sensors 24, 31 is performed. In this case, the measurement value acquired from the non-contact sensors 24 and 31 is compared with the measurement value acquired from the point sensor 50. In one embodiment, these two measurements preferably have the same coordinate representation given to the surface profile of the measured part. Alternatively, the measured value obtained from the point sensor 50 is compared with the measured value obtained from the non-contact sensors 24, 31 that are closest in distance to the point sensor 50 measured value. In either case, if both measured values are not equal or if the measured value from the non-contact sensor 24 or 31 is not within the predetermined range of the measured value of the point sensor 50, the non-contact sensor 24 or 31 Is calibrated to the measured value of the point sensor 50.

  As shown in FIG. 4, the processor 34 or other processing means capable of accessing data depending on the data stored in the data acquisition system 30 and received from the non-contact sensors 24 and 31 is monitored. Data representing a map of the surface of the part may be generated. In the case of the thermal sensor 24, the map shown in FIG. 4 is a thermal map of a defined area 60 in the field of view of the non-contact sensor 24. As shown, this map consists of color-coded areas A, B, and C. Here, each color represents an individual temperature measurement and / or a temperature range of the corresponding area of the surface of the part. As shown, FIG. 4 includes different markings and shades representing different colors and temperature measurements, or ranges of temperature measurements, as provided by the adjacent bar display 64.

  For purposes of illustrating the present invention, a thermal map image generated from data received from a non-contact temperature 24 sensor has been described, but the map image detects the vibration mode of other non-contact sensors, eg, turbine components. It can be generated from data received from sensor 31.

  The data relating to the blade profile or blade shape is provided in the form of a Cartesian coordinate system representing the blade profile of the stationary blade or blade corresponding to the axis of rotation of the shaft 20. Thus, there is one or more X, Y, and Z coordinates for each color zone A, B, or C of the mapped surface. These coordinates represent the location of a zone or point within a defined area and the temperature measurement or temperature range in that zone. Thus, the processor 34 or other processing means is configured to associate one or more of the mapped state measurements (i.e., temperature measurements) for the part with the corresponding X, Y, and Z coordinates.

  In addition, each point sensor 50 on the part is associated with a set of X, Y, and Z coordinates. In this way, the measurement values of the one or more non-contact sensors 24 corresponding to the coordinates of the point sensor 50 measurement values are specified. Using the data received from the point sensor 50, the processor 34 is configured to calibrate the stationary non-contact sensor 24 to provide a more accurate surface mapping of the blade 18 or 19. If the temperature measurement of the non-contact sensor 24 is not equal to or within the predetermined range of the temperature measurement obtained by the point sensor 50, the non-contact sensor 24 is calibrated and correspondingly The temperature is adjusted. In a preferred embodiment, not only is temperature measurement data received from the non-contact sensor 24 and having the same X, Y, and Z coordinates as the point sensor 50 temperature data adjusted, but also all temperatures across the thermal map. The measured value is adjusted.

  In Table 1 below, uncalibrated data measurements are listed according to the data received from the non-contact sensor 24 and point sensor 50 data measurements.

  As shown, the left half of Table 1 includes temperature measurements for each of the color zones A, B, and C of the thermal map, and representative coordinates for each measurement. The right column includes the temperature measurement received from the point sensor 50 and the corresponding coordinates. In addition, data representing the date and time the measurement was taken is further provided so that the measurement from the point sensor 50 can be compared with the measurement from the non-contact sensor 24 or 31. The processor 34 is programmed to compare the point sensor temperature measurements or data with the non-contact sensor 24 temperature measurement data having corresponding X, Y, and Z coordinates.

  Table 2 below shows temperature measurement data calibrated according to the point sensor 50 temperature measurement.

  As shown in Table 2 above, the data measurements in each of the zones A, B, and C are calibrated according to the temperature measurements received from the point sensor 50.

  The non-contact sensor 31 that detects the vibration mode of the part can be similarly calibrated. That is, a three-dimensional surface map is generated from data received from sensor 31 that provides measurement data related to vibration measurements across the surface of the part. In addition, point sensors, such as strain gauges, are used to calibrate the surface area data. Database 36 includes data representing the profile of the part being monitored, including a Cartesian coordinate system that provides the orientation of the part profile relative to the point of rotation or axis of rotation. For example, the X, Y, and Z coordinates of the blade profile for blades 18, 19 or vanes 22, 23 are provided corresponding to the axis of rotation of the shaft. A wing profile is provided that represents the surface profile of the part in a stationary or non-operating state. This wing profile represents an origin map for measuring part deflection, twist, or elongation.

  During operation of the turbine machine, data received from the non-contact sensor 31 is used to generate a three-dimensional map or profile of the part. This profile is compared with the original profile to determine the amplitude or magnitude of the displacement for the defined area 62 of the part or for certain coordinates within the defined area 62. The data collected from the non-contact sensor 31 is compared with the point sensor 50 data for the purpose of calibrating the non-contact sensor data.

FIG. 5 shows a flow chart or process diagram that includes steps of a method for monitoring the operational status of components of a turbine machine. In step 70, the non-contact sensor detects the operating state of the turbine machine, for example, the operating state of a compressor or a stationary blade or blade in the turbine, and transmits a data signal representing the surface area measurement of the detected operating state. To do. In step 72, data representing the measured values obtained from the non-contact sensor is transmitted to the data acquisition and control system as described. In step 74, the point sensor 50 mounted on the turbine or compressor component detects the same operating condition as detected by the non-contact sensors 24,31. In step 76 , data representing the measured values acquired by the point sensor 50 is transmitted to the data acquisition and control system.

  In a preferred embodiment, the data acquisition and control system 30 is configured to record data in relation to the date and / or time acquired from the non-contact sensors 24, 31 and the point sensor 50. In addition, the data acquisition and control system is programmed to identify the position of one or more measurement values acquired by the non-contact sensors 24, 31 and the coordinates representing the measurement values acquired by the point sensor 50. Yes. Accordingly, in step 78, the measured value data associated with the non-contact sensors 24, 31 is compared with the point sensor 50 data, so in the comparison step 80, data regarding date, time, and location are stored in the non-contact sensors 24, A comparison can be made for 31 calibration purposes.

  For this purpose, in step 80, the data control system 30 compares the non-contact sensor measurement data with the point sensor measurement data. If the non-contact sensor measurement is not equal to the point sensor measurement data or is not within the predetermined range of the point sensor measurement data, the non-contact sensor 24 or 31 and the corresponding measurement data are , Based on the corresponding point sensor 50 measurement data, as described in step 82. As explained above, the non-contact sensors 24, 31 take multiple state measurements over a defined area. Each such measurement is based on the point sensor 50 measurement data and the corresponding non-contact sensor 24, 31 measurement data identified by the data control system 30. In this way, a more accurate surface map of the monitored operating condition is generated.

  While preferred embodiments of the invention have been illustrated and described herein, it will be appreciated that such embodiments have been provided by way of example only. Many variations, modifications, and substitutions will occur to those skilled in the art without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.

DESCRIPTION OF SYMBOLS 10 Turbine machine, combustion turbine engine 12 Compressor 14 Combustor 16 Turbine 18 Turbine machine part, blade 19 Compressor machine part, blade 20 Central shaft, rotor shaft 22 Turbine machine part, stationary blade 23 Compressor machine part, stationary blade 24 Contact sensor, non-intrusion sensor, thermal sensor 26 Thermal barrier coating 30 Monitoring and data acquisition system, data acquisition and control system 31 Non-contact sensor, non-intrusion sensor 32 Antenna 33 Receiver 34 Processor, CPU
36 Database 38 Display 50 Point sensor 52 Connector 54 Transmitter 58 Casing 60 Defined area 62 Defined area A Color coding area, Color area B Color coding area, Color area C Color coding area, Color area

Claims (24)

A diagnostic system for monitoring the operating state of components of a turbine machine,
A non-contact sensor disposed relative to the turbine machine at a distance from the turbine machine component and detecting an operating state of the turbine component, the defined region of the component being determined by a field of view of the sensor A non-contact sensor that generates a data signal representing the operating state;
A wireless point sensor mounted on the turbine component and arranged at a predetermined coordinate with respect to the component on the turbine component, and monitoring the same operation state as the non-contact sensor and representing the operation state Or at least one wireless point sensor that generates a data signal;
A data acquisition and processing controller connected by data communication with the non-contact sensor and the wireless point sensor, using the operation state data from the wireless point sensor, the non-contact sensor, or the non-contact sensor The controller configured to calibrate data received from the non-contact sensor to detect the operating condition in a first estimated accuracy range, and the wireless point sensor to the first A diagnostic system configured to detect the operation state in a second estimated accuracy range higher than the estimated accuracy range.   The wireless point sensor is disposed on the turbine component in a field of view of the non-contact sensor and in the defined area of the turbine component monitored by the non-contact sensor. The diagnostic system according to 1.   At least one of the wireless point sensors is disposed on the turbine component in the field of view of the non-contact sensor and in the defined area of the turbine component monitored by the non-contact sensor. The diagnostic system according to claim 1.   The diagnostic system of claim 1, wherein during operation of the turbine, the part moves into and out of the field of view of the non-contact sensor.   The diagnostic system of claim 4, wherein the component is a turbine blade of the turbine machine including a plurality of turbine blades rotating about a rotation axis of the turbine machine in a turbine stage.   The diagnostic system according to claim 1, wherein the operating state is a surface temperature, a vibration mode, or a strain of the component.   The diagnostic of claim 1, wherein the operating condition is strain of the part, chemical composition of gas flow across the part, gas velocity across the part, gas pressure across the part, or wear or cracking of the part. system. The non-contact sensor transmits data relating to a plurality of measurements of the operating state over the defined area, and coordinates of one or more of these measurements are identified, and the coordinates of the wireless point sensor The data of at least one such measurement having specified coordinates that are the same or within a predetermined range of the wireless point sensor coordinates is calibrated based on the wireless point sensor data. 2. The diagnostic system according to 2. Based on calibration of the calibrated data of the one or more measurements from the non-contact sensor having the same coordinates as the wireless point sensor coordinates, or coordinates within a predetermined range of the wireless point sensor coordinates, The diagnostic system of claim 1, wherein a plurality of non-contact sensor measurement data is calibrated.   The data acquisition and processing controller is configured online to provide measurements and data calibration in real time, or the data acquisition and processing controller is configured to provide offline processed values and data calibration The diagnostic system according to claim 1. A diagnostic system for monitoring the operating state of components of a turbine machine,
A non-contact sensor disposed relative to the turbine machine at a distance from the turbine machine component and detecting an operating state of the turbine component, the defined region of the component being determined by a field of view of the sensor A non-contact sensor that generates a data signal representing the operating state;
A wireless point sensor mounted on the turbine component and disposed on the turbine at a predetermined coordinate relative to the component and in a defined area monitored by the non-contact sensor; At least one wireless point sensor that monitors the same operating state as the non-contact sensor and generates a data signal representative of the operating state;
A data acquisition and processing controller coupled in data communication with the non-contact sensor and the wireless point sensor, generated by the non-contact sensor compared to high fidelity data or data signals generated by the wireless point sensor The controller configured to calibrate the generated low fidelity data or data signal, the non-contact sensor comprising: a low fidelity data or data signal compared to the data or data signal generated by the wireless point sensor; A diagnostic system that provides a data signal and wherein the wireless point sensor is configured to provide a high fidelity signal compared to the data or data signal generated by the non-contact sensor. The data acquisition and processing controller comprises data related to a turbine part profile, the data including coordinates of the profile and coordinate data of the wireless point sensor on the part, the controller receiving by the non-contact sensor. Coordinate of the operating state data received from the non-contact sensor that is the same as the coordinate data of the wireless point sensor or within a predetermined range of the coordinate data to calibrate the measured low fidelity data or data signal The diagnostic system of claim 11, wherein the diagnostic system is configured to identify The operation wherein the operating state data received from the non-contact sensor includes a plurality of measured values of the operating state detected over the defined area and has the same coordinates or coordinates within a predetermined range of the wireless point sensor The diagnostic system of claim 12, wherein data associated with the plurality of measurements is calibrated based on state calibration.   The turbine component includes a plurality of components in a single stage of the turbine, and the non-contact sensor indicates an operating state of the same one or more components in the turbine stage of the component in the stage. The diagnostic system of claim 11, detecting as representing the detected operating state for each.   The diagnostic system of claim 14, wherein the component is a turbine or compressor vane, or a rotating blade of a turbine or compressor. A diagnostic method for monitoring the operating state of components of a turbine machine,
Detecting an operating condition associated with the part from a fixed position spaced from the part over a defined area of the part of the turbine machine;
Detecting the same operating state associated with the part from at least one position on the part having predetermined coordinates within the defined area on the part;
Generating low fidelity data or a data signal representing the operating state from the fixed position and the spaced position;
Generating high fidelity data or data signals representing the same operating state from the at least one point on the component;
Processing the low fidelity data or data signal and the high fidelity data and data signal to calibrate the low fidelity data and data signal compared to the high fidelity data and data signal. The turbine machine comprises a plurality of stages and includes a plurality of similar parts in each stage, the plurality of similar parts working synchronously to perform a desired function for operation of the turbine machine; further,
Detecting an operating condition on a plurality of said similar parts over a defined area of each such part from one or more fixed positions spaced from each part relative to said part; ,
Detecting the same operational state associated with the one or more parts from a position on the part having predetermined coordinates within the defined area on one or more of the plurality of parts; The diagnostic method of Claim 16 containing these.   18. The diagnostic of claim 17, wherein the step of detecting the operating condition at a point on the one or more similar parts comprises detecting the operating condition on only one part. Method.   The diagnosis method according to claim 17, wherein the similar component moves relative to the fixed position where the operation state is detected.   The diagnostic method according to claim 17, wherein the similar component is stationary with respect to the fixed position where the operation state is detected.   The diagnostic method of claim 17, wherein the step of detecting the operational state at one point on the part includes detecting the operational state on at least one part instead of all parts.   Processing the low fidelity data or data signal and the high fidelity data and data signal represents an operating state for one of the similar components to calibrate the low fidelity data relative to the high fidelity data. The diagnostic method of claim 16, comprising processing the high fidelity data representing the same operating state for the other one of the low fidelity data and the similar component. Identifying low fidelity data coordinates representing measured values of the operating state having the same coordinates as the position coordinates at which the operating state is detected to generate the high fidelity data or coordinates within a predetermined range;
The method of claim 16, further comprising: calibrating the low fidelity data at the identified coordinates compared to the high fidelity data. The step of generating low fidelity data representative of the operating state includes generating a plurality of measurements of the operating state, and the step of identifying coordinates of the low fidelity data comprises at least one of the operating states 24. The diagnostic method of claim 23, comprising identifying measurement coordinates, wherein the step of calibrating the low fidelity data includes calibrating data representing a plurality of measurements of the operating state.

Images